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 Fastener Technology International — April/May 2012 

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 All translations are provided for your convenience by the Google Translate Tool. The publishers, authors, and digital roviders of this publication are not responsible for any errors that may occur during the translation process. If you intend 

on relying upon the translation for any purpose other than your own casual enjoyment, you should have this publicationrofessionally translated at your own expense. 

Having The Right Axes Solves ProblemsHarvinder Singh Taking the correct steps to ensure sustained production improvement means looking for the ultimate in mill/turntechnology involving multiple-axis capabilities.

Fastener manufacturers are always on the lookout for costreducing, productivity-enhancing solutions for theiroperations. A proper review of the key performance metrics often uncovers the economic utility of improved processbenefits. Often it’s just a case of applying the right number of axes to the job at hand.  

Multi-Axis Turning Machines

Ganesh Machinery offers a comprehensive line of unique multi-axis turning machines designed to reduce fastenerproduction cost and increase productivity by getting the complete job done in just one operation. The company’svalue-priced three-axis, 6000 RPM, 10 HP, gang-tooled, CNC lathe with 1" diameter ballscrews and hydraulic colletactuation is the strongest, heaviest and most powerful machine in its class. For CNC machines, the gang-tooledsolution is the fastest way to make fasteners, with the quickest tool-to-tool time available.

The Ganesh Cyclone GT-32 features rigid tapping, a bar capacity of 1-3/8" and offers quick-changeover tool bars andhigh tool-density solutions. When additional tooling is needed, an eight-station tool turret is available that has theunique ability to mount multiple tools in each tool station. For those machining cross holes, wire holes or Nylok slotson their fasteners, the GT-32 features a high-performance C axis, and both high-speed driven tools and uniqueservo-driven tools are available that can even rigid tap to get the job done in just one handling. A Traub A-32 or 5Ccollet chuck can be used and a 5" diameter, three-jaw hydraulic chuck is also available for larger work. Ganesh is theonly builder offering all of these flexible solutions on its value-priced gang-tooled CNC lathe.

For customers requiring a subspindle to complete their parts, Ganesh offers the GT-32 features on the unique sixaxis,6000 RPM, Cyclone GTS-32, which is the only 1-3/8" bar-capacity, dual-slide, gang-tooled, subspindle lathe on themarket, providing the fastest CNC solution to produce your fasteners. Each of the twin opposed spindles features asynchronized C axis and facilitates the transfer of the part so the job can be completed in one operation. The twinindependent gang-tool slides mount the tooling needed to finish the front and back side of the part simultaneously.The integral parts catcher places the finished part on a conveyor belt that removes the completed part from themachine. The GTS-32 features quick-setup tool bars and the ability to perform all of the operations necessary tomake the volumes and varieties of the complete part package in just a single operation.

When a full Y axis is required to machine the features on your fasteners, Ganesh offers the 1-3/8" bar-capacity, four-

 

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axis, 6000 RPM, Cyclone NCY-32 that features 18 tool positions with seven servo-driven live tools mounted in ½" ER-20 collet spindles. There are four radial live tools and three axial live tools in the standard machine configuration. Angular-driven tool capability is also available for those applications that require the machining of a feature at anyangle. The Y axis feature can be used on all of the tooling, and because of the way the axes are arranged, multipleinsert tools can also be employed to augment the tool count. In addition to the servo-driven live tools with rigidtapping capability, high-speed spindles can be easily added to the machine to finish additional operations.

Complex Fastener Production

For more complex fastener work, Ganesh offers the 1-3/8" bar-capacity, seven-axis, 6000 RPM, Cyclone CS-32 with27 tool positions and 11 driven tools and a subspindle. A synchronized C axis on both spindles orients the workpiecein the exact radial position required for transfer to the subspindle, and both the main and subspindle can machinethe part simultaneously. There are 18 tools available to machine on the front side of the part and 9 tools available forthe back side. The tool count can be increased by double tooling the static ID tool stations. Fast 1181-IPM rapidmoves cut the tool-to-tool time to a minimum to maximize the productivity of the machine. The CS-32 is thestrongest, heaviest and most powerful machine in its class, and offers the largest in-class ballscrews providing thestrength to support the use of rotary broaching to complete the part in just one operation.

For fasteners requiring up to 2" bar stock, Ganesh offers the eight-axis, 6000 RPM, Cyclone-52 TTMY with two 16-station tool turrets with a Y axis on the upper turret. All 32 tool stations can have 7 HP, 4000 RPM driven tools. TheBMT-65 tool system allows each tool station to have multiple cutting tools by having tools mounted on the front and

back of the holder, and even side-by-side on a toolholder to greatly increase the tool count. This not only provides allthe tooling for a complex workpiece, but also provides the opportunity to have multiple jobs setup on the machine atone time to minimize changeover time.

The Cyclone-52 machines the front and back side of the part simultaneously and ejects the part into a part gripperthat places it on the integral conveyor belt to move it outside of the machine. The powerful Mitsubishi M-720Lseamlessly controls the entire process.

Maximum Productivity

When even greater productivity is required, Ganesh offers the 11-axis, 6000 RPM, Cyclone 3TMY with three 16-station tool turrets. This 48-tool station machine has all of the advantages of the TTMY machine, with the ability toput three tools in the work simultaneously. Ample tooling availability makes it easier to take complete control of theprocess and optimize production, creating the balance needed to address your customers’ needs and keep you a step

ahead of the competition.

The 2" bar diameter, nine-axis, Cyclone 52-BY2 B-axis machine provides 35 tool positions with 12 B-axis live toolsthat can be used at any angle on both the main and subspindle. The 12 live B-axis tools can also be used for crossand axial machining, and all 18 live tool stations include 4000 RPM, ½", ER-20 collet spindles. The 20 HP, 6000 RPM,machine provides a separate Y axis for the main and subspindle to maximize the amount of work that can beperformed simultaneously. The Cyclone 52-BY2 allows for more process options and the ability to quote morecomplex geometries in a single handling for better production flow.

For even larger bar work, the four-axis Ganesh 7612-TMY offers 3" bar capacity and a 35 HP, 3500 RPM, spindle witha 12-station VDI-40 tool turret featuring quick-change toolholders. Any station can support the 7 HP live tooling in anaxial or radial tool orientation. The 4", Y-axis travel allows multiple ID or OD tools to be used in any static toolstation. There is also a 2" bar capacity version of the machine available.

Ergonomics & Efficiency

Ergonomics is clearly a big part of the design art at Ganesh. Of course, the substance underlying the style is whatleads to the productivity improvements that really matter. Benefits of the Ganesh machines shown here include abetter use of floor space as well as improved machine access for setup and operation. But the bottom line isimproved work flow and increased production through-put along with reducing set-up labor and changeover time.

Integral parts catchers, chip conveyors and coolant flow confirmation monitors are all standard equipment with thehigh-production custom solutions offered by Ganesh for your fastener work. Bar feeders, bar loaders, bowl feeders,automation, high-pressure coolant and a host of other solutions are available to increase your production on all

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Ganesh machines.

 At Ganesh we find that work has a tendency to gravitate to the shop with the most competitive solutions.

Taking the correct steps to ensure sustained production improvement should be a part of your growth plan. A call tohave Ganesh review your work and suggest a solution that fulfills your cost/benefit analysis should be the first stepin your process improvement plan. Www.ganeshmachinery.com

Company Profile: Ganesh Machinery offers machine solutions including milling machines, machining centers, lathesand screw machines. Ganesh understands the challenges involved in picking the right machines and the rightoptions. Its team of Applications Engineers can help in making the right decisions to improve manufacturingprocesses. Www.ganeshmachinery.com